Wall construction system

ABSTRACT

A construction system utilizes a plurality of pre-manufactured units to form a concrete wall. Structurally, each pre-manufactured unit includes a wallboard mounted to an insulation board. Specifically, each wallboard has a first surface and an opposite second surface parallel thereto. For each wallboard, the insulation board is mounted to the second surface of the wallboard and extends to a face substantially parallel to the surfaces. In addition to the pre-manufactured units, the system comprises a temporary backing frame constructed from commercially-available aluminum forms which establish a wall. Also, the system includes a plurality of ties for supporting the units at a desired distance from the backing frame to establish a cavity for receiving concrete to form the concrete wall. After the concrete wall is formed, the backing frame is removed and the pre-manufactured units remain bonded to the wall.

FIELD OF THE INVENTION

The present invention pertains generally to concrete wall constructions.More particularly, the present invention pertains to systems and methodsfor forming concrete walls with pre-manufactured units. The presentinvention is particularly, but not exclusively, useful as a wall formingsystem and method that results in concrete walls bonded to insulationboard and finished with wallboards.

BACKGROUND OF THE INVENTION

Typically, interior and exterior concrete walls are constructed usingtemporary removable form members. These form members are often wooden,synthetic resin or metal. Generally, each wooden form member comprisesplywood boards and bridges for interconnecting with adjacent boards. Inorder to assemble a concrete formwork, the reinforcing bridges ofadjacent form members are usually fastened to each other with nails.When assembled, the formwork defines a cavity where the concrete wallwill be formed. After the concrete wall is formed, the wooden formworkis removed from the concrete wall.

During construction of a wall, the concrete is poured into the cavityand sets. While setting, moisture from the concrete mix is absorbed bythe wooden form member. Due to high water absorptivity of the woodenform member, the concrete loses an ideal water-cement ratio in itssurface portion adjacent the wooden form member. As a result, thefinished concrete's outer surface is roughened. Occasionally, the roughappearance of the concrete's outer surface leads to the conclusion thatthe concrete has defectively hardened. Therefore, to avoid this result,the wooden form member may be painted beforehand to reduce its waterabsorptivity. However, painted form members are high-priced and stillmay suffer from too much water absorptivity.

While synthetic resin form members do not suffer from water absorptivitylike wooden forms, they are generally very heavy and difficult to workwith. Further, they often fail to provide sufficient strength and arehigh-priced.

Also, metal form members suffer from working difficulties associatedwith great weight. In order to avoid such problems, metal forms arefrequently made as thinly as possible. As a result, although the metalitself is relatively strong, the metal formwork has limited strength.Further, metal is prone to corrosion, oxidation and deformation as aresult of use.

Regardless of the type of formwork used, the current practice is toassemble the formwork to create a cavity to receive poured concrete.After the concrete sets as a wall, the entire formwork is removed toleave the concrete wall.

In light of the above, it is an object of the present invention toprovide a permanently positioned concrete wall forming system. Morespecifically, it is an object of the invention to provide a system thatutilizes pre-manufactured units for forming concrete walls. Anotherobject of the present invention is to provide a pre-manufactured unitcomprising insulation board material mounted to a finished wallwallboard. Still another object of the present invention is to provide aconcrete wall forming system that eliminates absorption of water fromthe concrete while the concrete sets. Another object of the presentinvention is to provide a system that utilizes pre-manufactured units inconjunction with commercially-available aluminum forms to form concretewalls. Yet another object of the present invention is to provide aconcrete wall forming system and method that is easy to implement, issimple to use, and is comparatively cost effective.

SUMMARY OF THE INVENTION

In accordance with the present invention, a construction system isprovided for forming concrete walls. Structurally, the constructionsystem includes a plurality of pre-manufactured units. Thesepre-manufactured units are used to erect a boundary for one side of theconcrete wall, while a removable backing frame erected fromcommercially-available aluminum forms bounds the opposite side of theconcrete wall. After the concrete sets into the concrete wall, thebacking frame is removed and the pre-manufactured units remain bonded tothe concrete wall.

For the system, each unit defines an axis and comprises a wallboard andan insulation board. Further, each wallboard includes an exteriorsurface and a parallel opposite surface. Also, the insulation board ismounted to the opposite surface of the wallboard and extends to a facethat is parallel to the surfaces.

As noted, the system further includes a temporary backing frame that hasa wall distanced from the face of the insulation board. Also, flat tiesare provided for supporting the units at a desired distance from thebacking frame. As a result, a formwork defining a cavity between theunits and the backing frame is established for receiving concrete.During formation of the concrete wall, the face of the insulation boardand the wall of the backing frame bound the concrete.

After formation of the concrete wall, the backing frame is removed.However, the pre-manufactured units are permanently bonded to theconcrete wall and form part of the finished wall. Because thepre-manufactured units bound only one side of the concrete wall in thepresent invention, the need for the aluminum forms of the backing frameduring wall construction is reduced by half over current practices.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of this invention, as well as the invention itself,both as to its structure and its operation, will be best understood fromthe accompanying drawings, taken in conjunction with the accompanyingdescription, in which similar reference characters refer to similarparts, and in which:

FIG. 1 is a perspective view of a portion of a wall construction system;

FIG. 2A is perspective view of a portion of a finished wall erected witha wall construction system;

FIG. 2B is a cross sectional view of a finished wall taken along line2-2 in FIG. 2A, with external studs included;

FIG. 2C is a cross sectional view of a finished wall similar to that ofFIG. 2B, with studs provided internally, and with the interconnectionbetween adjacent pre-manufactured units illustrated;

FIG. 3A is a cross sectional view of the interconnection between thewallboard and the insulation board taken along line 3-3 in FIG. 2A;

FIG. 3B is a cross sectional view of an alternative interconnectionbetween the wallboard and the insulation board similar to FIG. 3A;

FIG. 4A is a perspective view showing the interconnection between a flattie and a brace at the edge of a pre-manufactured unit;

FIG. 4B is a cross sectional view of a wall construction system afterformation of a concrete wall as would be seen along line 4-4 in FIG. 4Aafter the addition of another pre-manufactured unit, and illustratingthe concrete wall with a backing frame;

FIG. 5A is a perspective view showing the interconnection between awallboard and an insulation board;

FIG. 5B is a cross sectional view of a wall construction system afterformation of a concrete wall taken along line 5B-5B in FIG. 5A, andillustrating the concrete wall and backing frame;

FIG. 5C is a cross sectional view of a wall construction system afterformation of a concrete wall taken along line 5C-5C in FIG. 5A, andillustrating the concrete wall and backing frame;

FIG. 6A is a perspective view of the intermediate plate and clip used toconnect the insulation board to the wallboard;

FIG. 6B is a cross sectional view similar to FIGS. 5B and 5C andfocusing on the intermediate plate during tightening of the clip;

FIG. 6C is a cross sectional view showing the intermediate plate of FIG.6B after the clip is locked into position;

FIG. 7A is a perspective view of a bracket used for interconnectingadjacent pre-manufactured units to a tie plate;

FIG. 7B is a cross sectional view of the bracket of FIG. 7A showninterconnecting adjacent pre-manufactured units to a tie plate;

FIG. 8A is a perspective view of a tie sleeve for positioning a tieplate at a non-interface location on a pre-manufactured unit; and

FIG. 8B is a cross sectional view of the tie sleeve of FIG. 8A shown inengagement with a pre-manufactured unit with a flat tie passingtherethrough.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIG. 1, a wall construction system is shown andgenerally designated 10. As shown in FIG. 1, the system 10 includes aplurality of pre-manufactured units 12 comprised of a wallboard 14mounted to an insulation board 16. For interior use, the wallboard 14 ispreferably gypsum board or drywall. For exterior use, the wallboard 14is preferably oriented strand board (OSB). The insulation board 16 isgenerally a plastic foam product such as expanded polystyrene.Importantly, such a plastic foam product adheres well to concrete.

As shown, each unit 12 defines an axis 18. Further, the wallboard 14includes a planar exterior surface 20 that is substantially parallel tothe axis 18. Likewise, the wallboard 14 forms a planar opposite surface22 that is substantially parallel to the exterior surface 20. As shown,the insulation board 16 is mounted to the opposite surface 22 of thewallboard 14 and extends to a face 24 that is substantially parallel tothe surfaces 20, 22.

In FIG. 1, the units 12 are used with a temporary backing frame 26,which may be created from commercially-available aluminum forms.Structurally, the backing frame 26 includes a wall 28 that is distancedfrom the insulation board 16. Together, the units 12 and the backingframe 26 define a formwork 30 having a cavity 32 for receiving pouredconcrete 34.

Referring now to FIGS. 2A and 2B, a portion of a finished wall 36 formedfrom a system 10, such as that shown in FIG. 1, is illustrated. In FIGS.2A and 2B, it may be seen that the backing frame 26 (shown in FIG. 1)has been removed while the units 12 remain bonded to the concrete wall38. In FIGS. 2A and 2B, the unit 12 a illustrated includes analternative construction that provides for additional support during theconcrete pouring and setting operation. Specifically, the unit 12 aincludes a series of cut-outs or grooves 40 that are substantiallyparallel to the axis 18.

In FIGS. 2A and 2B, the length of the unit 12 a is three feet whichcorresponds to the length of standard commercially-available backingframes 26 (shown in FIG. 1). For the unit 12 a, the cut-outs 40 arepositioned one foot apart, on center. Also, each cut-out 40 has a widthof four inches and a depth of two inches and is bounded on three sidesby the wallboard 14. During erection of the concrete wall 38, 2×4 studs42 (shown in FIG. 2B) are positioned in the cut-outs 40 for bracingpurposes. After the poured concrete 34 (shown in FIG. 1) sets to formthe concrete wall 38, the studs 42 can be removed. At that time, utilityfeatures 44 such as electrical conduit, outlet, gas piping, AV cabling,phone wiring and the like may be positioned in the cut-outs 40. Further,the unit 12 a forms conduits 46 substantially perpendicular to the axis18 for passing through the cut-outs 40. Preferably, conduits 46 arepositioned sixteen inches and forty-five inches from the floor,respectively. Alternatively or additionally, cut-outs 40 that areperpendicular to the axis 18 may be provided in the units 12.

Referring to FIG. 2C, another alternative unit 12 b is illustrated. Asshown, this unit 12 b includes studs 42 at an internal position betweenthe wallboard 14 and the insulation board 16. Again, the studs 42 areused to provide bracing to withstand the concrete 34 (shown in FIG. 1)pressure during formation of the concrete wall 38. As a result,formworks 30 (shown in FIG. 1) using units 12 b with internal studs 42require less additional bracing. Also, because the studs 42 are notremoved from the units 12 b after formation of the concrete wall 38,various external sidings and interior wall material may be convenientlynailed or screwed into the studs 42 through the wallboard 14. While notshown, the unit 12 b may also include conduits 46 for receiving utilityfeatures. Further, while not illustrated in FIGS. 2A-2C, the units 12preferably include small vertical channels at the boundary 48 betweenthe wallboard 14 and the insulation board 16 in order to avoidcondensation problems.

Cross-referencing FIG. 2A with FIG. 2C, the interconnection betweenadjacent units 12 may be understood. In FIG. 2A, the unit 12 a is shownhaving a planar first end 50 and a planar second end 52. For such aconstruction, units 12 that are adjacent one another in the formwork 30(shown in FIG. 1) may be interconnected by an adhesive tape or glue 54positioned on the ends 50, 52. Alternatively or additionally, as shownin FIG. 2C, the units 12 may include interlocking ends 50, 52.Specifically, the first end 50 of each unit 12 may form a notch 56between the wallboard 14 and the insulation board 16. Accordingly, areciprocating protrusion 58 is formed by the insulation board 16 at thesecond end 52. As can be seen in FIG. 2C, the ends 50, 52 of adjacentunits 12 are fitted together to provide mechanical interconnectionbetween the notches 56 and protrusions 58. This design effectivelycombats watery concrete seepage through the formwork 30 (shown in FIG.1).

Referring now to FIGS. 3A and 3B, the interconnection between thewallboard 14 and the insulation board 16 in a unit 12 is illustrated.Generally, an adhesive (not shown) may be used at the boundary 48 tobond the wallboard 14 to the insulation board 16. However, the use ofadhesive sometimes results in adverse effects to human health due tochemical vapors. In fact, adhesives are prohibited from use inconnecting wallboard 14 to insulation board 16 in certain applications.Also, the use of adhesives can result in condensation problems duringthe concrete setting stage. Therefore, the present units 12 are providedwith a mechanical fastening between the wallboard 14 and the insulationboard 16.

As shown in FIGS. 3A and 3B, fasteners 60 are provided to interconnectthe wallboard 14 and the insulation board 16. In FIG. 3A, the fastener60 is a bolt that includes a shaft 62 having a proximal end 64 and adistal end 66. Further, the fastener 60 includes a head 68 at theproximal end 64 of the shaft 62. Also, a receiver 70, such as adouble-ended female coupling, engages the distal end 66 of the shaft 62.For purposes of mechanical engagement, the receiver 70 includes a capportion 72.

As shown in FIG. 3A, the fastener 60 is driven through the wallboard 14and insulation board 16 until the head 68 of the fastener 60 abutsagainst the exterior surface 20 of the wallboard 14. Further, thereceiver 70 is driven into the insulation board 16 through the face 24to engage with the distal end 66 of the shaft 62. As the receiver 70 isscrewed onto the shaft 62, the cap portion 72 of the receiver 70 abutsthe face 24 of the insulation board 16 to compress the insulation board16 against the wallboard 14.

As shown in FIG. 3A, the receiver 70 further provides for threadedattachment to an extension rod 74. Further, the extension rod 74 may bemounted to a plate 76. As shown, after concrete 34 (shown in FIG. 1) ispoured and sets into a concrete wall 38, the plate 76 anchors the unit12 to the wall 38. Also, the plate 76 may include holes for receivingwire that may be connected to rebar in the concrete wall 38. Preferably,the wallboard 14 and insulation board 16 are prepared with holes locatedfor receiving the fastener 60 and receiver 70 in alignment.

In FIG. 3B, an alternate method of fastening the wallboard 14 to theinsulation board 16 is shown. In FIG. 3B, the fastener 60 is a screwhaving a proximal end 64 with a head 68 and a distal end 66 with anaperture 78. As shown, the fastener 60 is screwed into the wallboard 14and insulation board 16 until the head 68 abuts the wallboard 14.Thereafter, a wire 80 is passed through the aperture 78 and connected torebar 82. After the concrete 34 is poured and sets into the concretewall 38, the connection between the rebar 82 and the fastener 60 mountsthe wallboard 14 to the insulation board 16.

Referring now to FIGS. 4A and 4B, the interconnection between the units12 and the backing frame 26 is illustrated. Specifically, FIG. 4Aprovides a perspective view of a single unit 12 for clarity, while FIG.4B shows two adjacent units 12 connected to a backing frame 26, afterformation of the concrete wall 38.

In order to interconnect the units 12 to the backing frame 26, a flattie 84 is provided at multiple positions along the interface 86 betweenadjacent units 12. Generally, commercially-available backing frames 26include sections that are three feet by eight or nine feet. Further,five to six flat ties 84 are generally used at each interface 86 betweenadjacent units 12.

As shown, the flat tie 84 has a first end 88 at the wallboard 14 and asecond end 90 at the backing frame 26. Further, a hole 92 is provided ateach end 88, 90 of the tie 84. Because the unit 12 lacks sufficientstrength to hold the tie 84 directly, a brace 94 is positioned on theexterior surface 20 of the wallboard 14 of adjacent units 12 along bothsides of the interface 86. For purposes of the present invention, thebraces 94 may extend for the entire height of the units 12. As shown,each brace 94 is provided with a plurality of holes 96 forinterconnection with the first end 88 of the flat tie 84. Specifically,a pin 98 is passed through the hole 92 in the first end 88 of the flattie 84 and the selected holes 96 in the braces 94. Also a wedge 100 isused between the pin 98 and the unit 12 to hold the pin 98 in place.

In FIG. 4B, it can be seen that the second end 90 of the flat tie 84 isconnected to the backing frame 26. Specifically, the backing frame 26includes a pair of tabs 102 formed with holes 104 for alignment with thehole 92 in the second end 90 of the flat tie 84. As shown, a pin 106passes through the holes 92, 104 to engage the flat tie 84 to thebacking frame 26. As can be seen from FIG. 4B, the flat tie 84 maintainsthe distance 108 between the unit 12 and the backing frame 26. As aresult, the distance 108 may be selected to ensure that the concretewall 38 has the desired thickness.

As shown in FIG. 4A, the flat tie 84 includes an engineered weakness 110at its second end 90. Structurally, the engineered weakness 110 may be apair of notches that reduce the width of the flat tie 84. As a result,after the backing frame 26 is removed from the concrete wall 38, theexposed second end 90 of the flat tie 84 may be easily separated fromthe rest of the flat tie 84 embedded in the concrete wall 38.Specifically, the second end 90 of the flat tie 84 may be hammered,causing it to break at the engineered weakness 110. As a result, theflat tie 84 is not exposed when the concrete wall 38 is finished.

Referring now to FIGS. 5A-5C, an alternative interconnection between theunits 12 and the backing frame 26 is illustrated. Specifically, FIG. 5Aprovides a perspective view of a single unit 12 for clarity, while FIGS.5B and 5C show two embodiments for connecting adjacent units 12 to abacking frame 26, after formation of the concrete wall 38.

Cross-referencing FIGS. 5A-5C, flat ties 84 are used to interconnect theunits to the backing frame 26. Unlike the flat ties 84 of FIGS. 4A and4B, the flat ties 84 illustrated in FIGS. 5A-5C do not require theadditional use of braces. Specifically, each flat tie 84 in FIGS. 5A-5Cincludes an end plate 112 at its first end 88 for mounting to adjacentunits 12. Preferably, the end plate 112 is about three inches by threeinches.

For the flat tie 84 a illustrated in FIGS. 5A and 5B, the end plate 112a is U-shaped and has a central portion 114 and two legs 116. As shown,the central portion 114 abuts the exterior surface 20 of the wallboard14 of adjacent units 12. Further, each leg 116 is received within a slot118 formed in the wallboard 14 of each adjacent unit 12. As a result,the end plate 112 is secured to each unit 12 and distributes stress oneach wallboard 14. In order to utilize a plurality of end plates 112having legs 116, the units 12 may be provided with slots 118 everytwelve to sixteen inches along each interface 86.

Alternatively, the flat tie 84 b may have an end plate 112 b asillustrated in FIGS. 5A and 5C. Specifically, the end plate 112 b isplanar and includes apertures 120 for receiving fasteners 122 such asnails or screws. As shown in FIGS. 5A and 5C, the end plate 112 b abutsthe exterior surface 20 of the wallboard 14 and the fasteners 122 aredriven into the insulation board 16. This design is particularlyeffective for wallboards 14 constructed from OSB because the OSBmaterial holds nails and screws well.

Still cross-referencing FIGS. 5A-5C, the flat ties 84 are secured to theinsulation board 16 of the units 12 with intermediate plates 124. Asidentified in FIG. 5B, the intermediate plates 124 are substantiallyU-shaped with a central portion 126 and teethed wings 128. As shown, thewings 128 extend through the face 24 into the insulation board 16.

Referring now to FIG. 6A, it can be seen that the central portion 126 ofthe intermediate plate 124 forms an opening 130 for receiving the flattie 84 (shown in FIGS. 5A-5C). In this embodiment, it is preferred thatthe flat tie 84 include graduated indentations (not illustrated) forengagement with the intermediate plate 124. In FIG. 6A, the centralportion 126 of the intermediate plate 124 forms a slot 131 parallel tothe opening 130. As further shown in FIG. 6A, a clip 132 is alsoprovided to lock the intermediate plate 124 in position. Structurally,the clip 132 includes a substantially planar main portion 134 having afirst edge 136 and a second edge 138. At the first edge 136, twocurvilinear arms 140 extend from the main portion 134 and curvegenerally in the direction of arrow 142. Further, the two arms 140 aredistanced from one another to define a gap 144 in conjunction with thefirst edge 136 for receiving the flat tie 84. As shown in FIG. 6A, theclip 132 further includes a tab 146 that extends from the second edge138 of the main portion 134 in the direction of arrow 148, i.e.,opposite the direction of arrow 142.

In FIGS. 6B and 6C, a cross section view of the intermediate plate 124and clip 132 is provided along line 6-6 in FIG. 6A, showing theintermediate plate 124 and clip 132 in use. Cross-referencing FIGS. 6Aand 6B, the flat tie 84 is received within the gap 144 of the clip 132,and the clip 132 is slid along the flat tie 84 until it contacts theintermediate plate 124. Then, as shown in FIG. 6C, the tab 146 of theclip 132 is forced through the slot 131 of the intermediate plate 124.This engagement mechanically fastens the intermediate plate 124 inconnection with the insulation board 16. Thereafter, the flat tie 84 maybe secured to the backing frame 26.

Referring now to FIGS. 7A and 7B, an alternative interconnection betweenadjacent units 12 and the backing frame 26 is illustrated. As shown inFIG. 7A, a bracket 150 includes a planar portion 152 that extends alongan axis 154 from a first end 156 to a second end 158. At each end 156,158, the bracket 150 is provided with apertures 160. Further, thebracket 150 forms a slot 162 which extends substantially perpendicularto the axis 154. As shown, the bracket 150 includes an upright portion164 with a length perpendicular to the axis 154, and a widthperpendicular to the axis 154. Structurally, the upright portion 164defines a channel 166 that is aligned with the slot 162. Further, theupright portion 164 includes an opening 168 parallel to the axis 154 forproviding access to the channel 166. Preferably, the bracket 150 has alength of fourteen inches and a width of at least two-and-one-halfinches, preferably three inches.

As shown in FIG. 7B, the bracket 150 is positioned on the exteriorsurfaces 20 of the wallboards 14 of adjacent units 12. Further, thechannel 166 and slot 162 (identified in FIG. 7A) are aligned with theinterface 86 between the adjacent units 12. As a result, the flat tie 84can pass through the channel 166 and slot 162 (in the direction of arrow169 in FIG. 7A), along the interface 86 and into connection with thebacking frame 26. As shown, a pin 170 is passed through the opening 168(shown in FIG. 7A) to hold the flat tie 84 relative to the bracket 150.Cross-referencing FIGS. 7A and 7B, fasteners 172 such as nails or screwsare driven through the apertures 160 at the ends 156, 158 of the planarportion 152 of the bracket 150 into studs 42 located within the units12.

Referring now to FIGS. 8A and 8B, a flat tie sleeve 174 is illustrated.In practice, the flat tie sleeve 174 is intended to provide anadditional location for a flat tie 84 (in addition to along theinterface 86 between adjacent units 12. Structurally, the sleeve 174includes a planar base portion 176 and a sleeve portion 178 that definesa pathway 180 through the sleeve 174. As shown in FIG. 8B, the sleeveportion 178 is forced through the wallboard 14 and into the insulationboard 16 of a unit 12. Further, the base portion 176 abuts the wallboard14. As a result, the sleeve 174 provides the pathway 180 through thewallboard 14 and a flat tie 84 may be passed through the unit 12 at anydesired location. In other words, placement of flat ties 84 is notlimited to interfaces 86 between adjacent units 12. This ability isparticularly beneficial when the widths of the wallboards 14 do notcorrespond to the widths of the backing frame 26, or around corners.

While the particular Wall Construction System as herein shown anddisclosed in detail is fully capable of obtaining the objects andproviding the advantages herein before stated, it is to be understoodthat it is merely illustrative of the presently preferred embodiments ofthe invention and that no limitations are intended to the details ofconstruction or design herein shown other than as described in theappended claims. It is noted that, while the dimensions represented inthis description are merely illustrative and not limiting, they areintended to provide for ease of use with backing frames constructed frompresently commercially-available aluminum forms.

1. A wall construction system comprising: a plurality ofpre-manufactured units, with each unit including a wallboard having afirst surface and an opposite second surface substantially parallelthereto, wherein each unit further comprises an insulation board mountedto the second surface of the wallboard and extending therefrom to a facesubstantially parallel to the second surface of the wallboard; atemporary backing frame distanced from the face of the insulation boardto establish a cavity therebetween; and a plurality of ties forsupporting the units at a desired distance from the backing frame forreceiving concrete in the cavity to create a concrete wall, wherein thebacking frame is removed after formation of the concrete wall, andwherein the pre-manufactured units are permanently bonded to theconcrete wall.
 2. A system as recited in claim 1 wherein the firstsurface of each wallboard forms at least one groove for receiving a studfor bracing during formation of the concrete wall, with said groovereceiving utility features after the stud is removed.
 3. A system asrecited in claim 2 wherein each unit defines a conduit extending betweengrooves for receiving utility features.
 4. A system as recited in claim1 wherein each unit further comprises at least one stud parallel to thesurfaces and positioned between the insulation board and the wallboardadjacent the second surface of the wallboard.
 5. A system as recited inclaim 1 further comprising a means for interconnecting adjacent units.6. A system as recited in claim 5 wherein the interconnecting meansincludes a notch formed between the wallboard and the insulation boardat a first end of each unit and a reciprocating protrusion formed by theinsulation board at a second end of each unit.
 7. A system as recited inclaim 1 further comprising fasteners for mounting the wallboard to theinsulation board.
 8. A system as recited in claim 7 wherein eachfastener includes a shaft having a proximal end and a distal end, with ahead mounted to the proximal end, wherein the shaft passes through thewallboard and the insulation board with the head abutting the firstsurface of the wallboard, and wherein a receiver engages the distal endof the shaft to hold the wallboard and insulation board therebetween. 9.A system as recited in claim 1 wherein an interface is establishedbetween each pair of adjacent pre-manufactured units, wherein each tieis positioned at an interface with a first end at the wallboard of thepre-manufactured unit and a second end at the backing frame.
 10. Asystem as recited in claim 9 wherein each tie includes an engineeredweakness at the second end to provide for separation of the second endfrom the tie after the backing plate has been removed.
 11. A system asrecited in claim 9 further comprising a brace positioned on the firstsurface of each wallboard at the interface, with the braces on adjacentpre-manufactured units surrounding the respective tie for connectiontherewith.
 12. A system as recited in claim 9 further comprising abracket positioned on the first surfaces of adjacent pre-manufacturedunits and spanning the interface therebetween, with the bracket formingan aperture for positioning the respective tie in the interface.
 13. Asystem as recited in claim 9 wherein each tie includes an end plate atthe first end for mounting to adjacent pre-manufactured units.
 14. Asystem as recited in claim 13 wherein the end plate of each tie isU-shaped and has a central portion and two legs, wherein the centralportion abuts the first surface of the wallboard of each adjacentpre-manufactured unit, and wherein each leg is received within a slotformed in the wallboard of each adjacent pre-manufactured unit.
 15. Asystem as recited in claim 1 further comprising a plurality ofintermediate plates positioned at the face of the insulation board,wherein each intermediate plate includes an opening, with a respectivetie passing through the opening, and wherein each intermediate plateincludes means for engaging the insulation board.
 16. A system asrecited in claim 1 further comprising a tie sleeve defining a channel,wherein the tie sleeve is forced through the wallboard and into theinsulation board at a desired position relative to the backing frame,and wherein a tie is positioned in the sleeve with a first end at thewallboard of the pre-manufactured unit and a second end at the backingframe.
 17. A wall construction which comprises: a substantially flatwallboard having a first surface and a second surface, wherein thesecond surface is substantially parallel to the first surface; aninsulation board mounted against the second surface of the wallboard; aconcrete wall formed against the insulation board to position theinsulation board between the wall board and the concrete wall, whereinthe concrete wall is formed with an external surface substantiallyparallel to the first surface of the wall board; and a plurality of tiesfor holding the wall board against the insulation board and forpositioning a backing frame at a distance from the insulation boardduring formation of the concrete wall, wherein the ties are subsequentlyused for anchoring the combination of wall board and insulation boardagainst the concrete wall after removal of the backing frame.
 18. Amethod for constructing a concrete wall comprising the steps of:arranging a plurality of pre-manufactured units, with each unitincluding a wallboard having a first surface and an opposite secondsurface substantially parallel thereto, wherein each unit furthercomprises an insulation board mounted to the second surface of thewallboard and extending to a face substantially parallel to the secondsurface for bounding concrete during formation of the concrete wall;erecting a temporary backing frame distanced from the face of theinsulation board; supporting the units at a desired distance from thebacking frame to establish a cavity therebetween; pouring concrete intothe cavity and setting the concrete therein to construct the concretewall; and removing the backing frame after formation of the concretewall, wherein the pre-manufactured units are permanently bonded to theconcrete wall.
 19. A method as recited in claim 18 wherein the arrangingstep is accomplished by interconnecting adjacent pre-manufactured units.20. A method as recited in claim 18 wherein the supporting step isaccomplished by connecting each pre-manufactured unit to a first end ofa respective tie and connecting the backing frame to a second end of therespective tie, and wherein the method further comprises the step ofseparating each second end from each tie after the backing frame isremoved.